Decentralized Biogas Plant for Small-Scale Industries

To address rising energy costs for small-scale food processing units, we implemented a decentralized biogas plant in a local jaggery production unit. This clean energy solution reduced operational costs by 30% and diverted 2 tons/month of organic waste from landfills, helping the unit become both cost-effective and eco-friendly.

Background

A jaggery (gur) production unit in Champawat, Uttarakhand, operated on firewood and diesel for heat energy, incurring high costs and releasing toxic emissions. With limited access to grid power and LPG, the business faced supply disruptions during peak production.

Problem Statement

The plant's profitability was threatened by increasing firewood costs and unsustainable waste disposal methods. Over 2 tons of sugarcane residue was discarded monthly.

Solution Provided

Our team installed a 15-cubic-meter biogas plant beside the jaggery production unit. Key features:

• Feedstock: Sugarcane bagasse, molasses, and water hyacinth

• Energy Output: ~4.5 cubic meters/day, used directly for boiling operations

• Wastewater Reuse: Slurry mixed with effluents used in organic farming

• A compact dual-burner setup was customized to integrate with existing boilers.

Results & Impact

This reduced reliance on traditional fuel, cut down emissions by over 75%, and created a new income stream through sale of surplus slurry to local farmers.

Conclusion

The project demonstrated how biogas can enhance industrial productivity while addressing environmental concerns. With minimal capital investment and a 1.5-year ROI, this model is now being considered for two textile dyeing units in the same region.